Scaling CO2 Electroreduction Revolution: Pathways from Laboratory Breakthroughs to Industrial Implementation

Abstract

Electrocatalytic CO2 reduction reaction (CO2RR) offers a sustainable pathway to convert CO2 into value‐added fuels and chemicals using renewable energy. Recent breakthroughs in catalyst engineering and reactor design have achieved industrial‐relevant current density (>1 A cm⁻2) and high Faradaic efficiency (FE) (>80% for C1/C2+ products), but the technology remains constrained to laboratory prototypes. This review critically examines the engineering challenges hindering industrial deployment of CO2RR systems, focusing on three key Operational parameters in scaling implementation electrolyzer architectures: membrane electrode assemblies (MEAs), solid oxide electrolyzer cells (SOECs), and modular stack designs. The operational bottlenecks in scaling these systems, including mass transport limitation, conversion efficiency, and long‐term stability under industrial current densities, are systematically analyzed. By correlating material innovations with reactor engineering strategies, the critical challenges for achieving energy‐efficient CO2 conversion at scale are identified. The review further outlines technological roadmaps addressing material scalability, system durability, sustainability with intermittent renewables, and techno‐economic feasibility. Emphasizing the synergy between electrochemical engineering and industrial manufacturing requirements, this work provides practical guidelines to bridge the lab‐to‐industry gap, accelerating CO2RR commercialization for global carbon neutrality goals.